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Operating instructions Open two-stage compressor FZ 16

1. Operating instructions Open two stage compressor FZ 16 E 0 112 01 00 Art No 09998 Page 1 KALTEMASCHINEN Operating instructions Open two stage compressor FZ 16 Type FZ 16 2051 R 22 FZX 16 2051 R 404 A FZX 16 2051 R 410A Operating instructions n two stage compressor FZ 16 Ope Stage comp E 0 112 01 00 Art No 09998 Page 2 KALTEMASCHINEN Contents Page d Safety INS MUCTIONS scrsorqontnsonenncinecssivsnneseneetasepatisanlnoeinetsnmuncsstidamaneceasepunensuened 3 2 Open two stage compressor FZ 16 eee eee eee 3 3 Bret CSS CNT aa oss cecmatatacinaestusiatadttediesune anaa eE E EN ARE EE 3 4 Main and function pants sss see eee eee eee eee d T Te 1 L 5 6 aceasta ten ge ee E E nna Aenea nega E teenies 5 FLAMES GP AD DIC ATOM TT 6 7 1 Absolute limits Of application esse eee eee eee eee 6 7 2 Limits of application FZ 16 2051 R 22 6 7 3 Limits of application FZ 16 2051 R 404 A 6 7 4 Limits of application FZ 16 2051 410 A 6 8 Description of functions FZ 16 2051 eee 7 8 1 Diagram to show a refrigerating plant with two stage comp FZ 16 2051 8 9 Installation INSTT UCHOINS ocx cee cees ade ctacaseuseencurtanes hoeuet ence etensyseneteubemniuencsmeseetoeleeonens 9 il e TT I 9 9 2 Pipe connections pipelines eee eee eee eee 9 9 3 Shutoff Valve Sosis AA ER SE 10 10 Initial COMMISSIONING arrisera rora ee e Eaua 11 10 1 Leak test evacuating cesses eee ata ee 11 10 2 Refrigerant Ta D 11 10 3
2. in liquid form at the evaporator intake Caution e Never top up with liquid refrigerant via the suction shut off valve on the compressor e Additives may not be added to oil and refrigerant Operating instructions n two stage compressor FZ 16 Ope g p E 0 112 01 00 Art No 09998 Page 12 KALTEMASCHINEN 10 3 Liquid shocks Special attention must be paid to the following to avoid liquid shocks e The whole refrigerating plant must be properly designed e All components must be rated to be compatible with each other with regard to output particularly evaporator and expansion valve e Suction gas overheating at the evaporator outlet should be min 7 10 K check setting of the thermostatic expansion valve e Particularly in the case of critical plant e g with several evaporator points suitable measures are recommended e g using liquid traps solenoid valve in the liquid pipe etc Caution Liquid shocks can cause damage to the compressor Important note In order to avoid liquid shocks on the HP side the solenoid valve for reinjection no 20 see diagram page 8 may not be opened until approx 15 20 seconds after switching on the compressor full load operation Switching off the compressor Close the solenoid valve approx 15 20 seconds before switching the compressor off 10 4 Lubrication oil check The oil level of the compressor is to be checked immediately after the start e Oil level 14 to of t
3. heat exchanger 6 via the expansion valve 7 to sub cool the refrigerant here in pipe 1 and then cool down the overheated refrigerant of the low pressure stage in the intermediate pressure chamber 3 which has been compressed to the intermediate pressure p Operating instructions Open two stage compressor FZ 16 E 0 112 01 00 Art No 09998 Page 8 KALTEMASCHINEN 8 1 Diagram to show a refrigerating plant with two stage compressors FZ 16 2051 23 22 21 20 19 18 17 16 15 14 13 12 l 4 R Fig 8 1 Compressor 13 Oil separator 2 Cylinder LP stage 14 Non return valve 3 Intermediate pressure chamber 15 Condenser 4 Intermediate pressure pipe 16 Refrigerant receiver 5 Cylinder HP stage 17 Filter drier 6 Panel heat exchanger 18 Solenoid valve 7 Expansion valve 19 Sight glass 8 Sight glass 1 4 20 Expansion valve evaporator 9 Sight glass 2 21 Evaporator 10 Solenoid valve 22 Liquid separator 11 Filter drier 23 Anti vibration pads suction pipe 12 Anti vibration pads pressure pipe FUE Liquid intermediate cooler inlet FUA Liquid intermediate coller outlet 1 components for the intermediate cooling system standard feature in scope of supply Operating instructions n two st ompr rFZ1 Rag S E 0 112 01 00 Art No 09998 Page 9 KALTEMASCHINEN 9 Installation instructions 9 1 General e Compressor and motor mounted rigid on joint base frame Anti vibration pads rubber pa
4. Liquid shoCkS sss 12 10 4 Lubrication Oil CHECK sescccacecstecexecccapsaraegeaicegualacsracseexcetterasecctecadiaatitetcanouee 12 10 5 Oil pressure safety switch eee 13 10 6 Oil SUMP heating inssin aaa aR E E AREE 13 10 7 Heat protection thermostat esse eee eee eee eee eee eee 13 10 8 Shaft SOA oc icete cedars naa soc saenvacecacencsadkeusmavawanswavananatadesadieesneacecaties 14 Ti Operaatio oresar a aeann Eaua Enana ideaan anae 15 Hel Statunloader srnec a E AE E E 15 VEZ TG SAMA vsscbossz aganaga neeaaea aaa aa aa aaa aa DEA 15 12 BRUNT 12T Tale 15 12 71 Bale INSTUCTIONS sectcceccdccartericiventiccimninianiaiannioutinaiiniietas 15 12 2 Service intervals sse eee 15 12 3 Recommended spare parts cesses esec e eee 16 12 4 Replacing the valve plates eee eee eee eee 16 12 5 Excerpt from the lubricant table esse eee eee eee ee 17 13 Technical data dimensions and connections cesses eee eee eee eee 18 13 1 Technical 2 1 ess as na E EE A EEEE 18 13 2 DIMENSION Siessen nnne e EEVEE E 18 Aid COOMMECTON sonra E E EEA 19 Bock GmbH amp Co K ltemaschinenfabrik Postfach 11 61 D 72632 Frickenhausen Benzstra e 7 D 72636 Frickenhausen Tel 49 70 22 94 54 0 Fax 49 70 22 94 54 137 mail bock de http www bock de certified by DQS according to Subject to change without notice DIN EN ISO 9001 Reg No 2177 Operating instructions ressor FZ 1 Open two stage compress 6 Kanna Art No 09998 Page 3 KALTEMASCHINEN 1 Safet
5. a dimensions and connections 13 1 Technical data E H ERE A FZX 1612051 ATO INo ofeyinders o Tes 595 Lubrication Forced circulation lubrication Oil pump independent of direction of rotation Oil grade for R 22 FUCHS DEA Reniso SP 46 Oil grade for R 404 A R 410 A FUCHS DEA Reniso Triton SE 55 Oil filing ives Compressor belt pulley Outer diameter mm 322 V belt profile DIN 7753 SPB No of grooves Min speed pm e pm bar par Table 3 13 2 Dimensions insulated with X P R SV A Al Vv ARMAFLEX Coolant tag Q S N FUA FUE Fig 19 E 0 112 01 00 Art No 09998 a Se a 9 Page 19 KALTEMASCHINEN Operating instructions Open two stage compressor FZ 16 13 3 Connections S H J Dim teraOST RB2_ FZX TOMBOST RADAA FZX TBROST RATOA 5472 1 26 1 318 GS 16 518 mm H Oil inlet plug mm M 22x 1 5 J Oil sump heating mm M 22x 1 5 mm L soldered connection Table 4
6. ds used for erection of base frame on foundation e Leave sufficient space for maintenance work e Mount the belt drive properly as follows The belt pulleys of compressor and drive motor must fit tightly and be in line Use only V belts with calibrated length Select centre to centre spacing V belt length and belt pre tension according to instructions provided by belt manufacturer Avoid belt flutter Check belt pre tension after running in period e Only lift compressor at the transport eyelets fig 9 and 10 transport eyelets Fig 10 9 2 Pipe connections pipelines Caution Compressor is under pressure inert gas Shut off valves should remain closed until evacuated Pipe connections are designed so that pipes in normal millimetre and inch dimensions can be used The soldering nipples of the shut off valves are to be removed from the shut off valves when soldering the pipes Pipelines and plant components must be thoroughly clean and dry on the inside and free of scales metal chips rust and phosphate layers The parts must also be delivered in an air tight seal Note All pipes are to be equipped with suitable vibration compensators Operating instructions Open two stage compressor FZ 16 E 0 112 01 00 Art No 09998 Page 10 KALTEMASCHINEN 9 3 Shut off valves Caution The two shut off valves suction shut off valve and pressure shut off valve must be opened before starting the compressor For l
7. ervicing tasks at regular intervals particularly recommended in the limit range at high temperatures and pressures e Oil change for the first time after approx 100 200 operating hours then once every twelve months Always clean the oil suction filter when changing the oil Note Used oil must be disposed of properly in line with national regulations e Function checks once every twelve months oil level compressor leaks running noises pressures temperatures functioning of the additional equipment e g solenoid valve in the intermediate cooling system oil pressure safety switch etc E 0 112 01 00 Art No 09998 Page 16 KALTEMASCHINEN Operating instructions Open two stage compressor FZ 16 12 3 Recommended spare parts The following table gives an overview of the most important spare parts Compressor type FZ 16 2051 R22 FZX 16 2051 R404A FZX 16 2051 R410A Gasket kit 08494 08012 Kit for valve plate low 08498 pressure side LP Kit for valve plate high 08499 pressur side HP 08795 Oil sump heating kit 230 V 08426 Tab 1 12 4 Replacing the valve plates The FZ compressors are divided into an LP and an HP compressing stage Different types of valve plates are required for the individual compressing stages because of the canal guidance Caution The valve plates of the LP and HP stage may not be confused during maintenance and repair work e f an LP valve plate is mounted to the HP cylinder head
8. he sight glass notch in sight glass min oil level oil should not fall below this fig 14 e Oil pressure control using a pressure gauge is possible if required via a Schrader connection oil level marking notch at the oil pump for connection position see min oil level page 18 fig 19 Oil differential pressure should be 1 5 4 0 bar over the whole application Fig 14 range e Automatic monitoring by standard oil differential pressure switch Troubleshooting should be carried out when the machine is switched off by this device observe instructions on the lid of the switch Caution If larger quantities of oil have to be topped up there is a risk of liquid shocks the oil return line must be checked Operating instructions two st ompressor FZ 1 Open stage compress 6 exten Art No 09998 Page 13 KALTEMASCHINEN 10 5 Oil pressure safety switch FZ 16 2051 is equipped with a differential pressure switch as a standard feature for automatic monitoring of the oil pressure Electrical connection according to the enclosed description Troubleshooting should be carried out when the machine is switched off by this device observe instructions on the lid of the switch 10 6 Oil sump heating Description see also DEF 1 39 Oil sump heating While the compressor is at a standstill refrigerant diffuses into the lubricating oil of the compressor housing depending on pressure and ambient temperature This reduce
9. ied e Then include the compressor in the subsequent evacuating procedure To do so open the compressor suction side and pressure shut off valve relieve pressure first Note As well as the suction respectively high pressure side the middle pressure area of the compressor also has to be evacuated use connection X see page 18 fig 19 The solenoid valve of the intermediate cooling system position 10 fig 8 should be open when doing so e Vacuum lt 1 5 mbar with pump shut off Repeat procedure several times as required e Machine is then dry and tight when the rise in pressure in the refrigerating system is lt 0 5 mbar 24 h with the vacuum pump switched off 10 2 Refrigerant filling e Check the oil level in the compressor before filling up The oil level must be visible in the sight glass e Check once again whether the compressor suction and pressure shut off valves are open e Top up the coolant breaking the vacuum with the machine switched off filling the liquid straight into the condenser respectively collector Note Ensure there is sufficient refrigerant in the machine before initial commissioning of the compressor Refrigerant must be visible without any bubbles in sight glasses 1 and 2 of the intermediate cooler e Start up the compressor If it is necessary to top up the refrigerant after initial commissioning this can take place either in gaseous form on the suction side or taking suitable precautions
10. lass 1 liquid pipe Sight glass 2 liquid pipe Filter dryer Solenoid valve Expansion valve Intermediate cooler inlet Intermediate cooler outlet Operating instructions n two stage compressor FZ 1 Ope 9 p S E 0 112 01 00 Art No 09998 Page 5 KALTEMASCHINEN 5 Nameplate The following information is contained on the compressor nameplate BOCK D 72636 Frickenhausen Kaltemaschinen Germany Typ FZX16 2051 R404A ae AE12345 001 Bauj 1998 ni 1400 min Vip 118 9 m h n 1450 n4800 min V Hp 59 5 m h n 1450 MAX BETR DRUCK ND HD 19 25 bar PRUF UBERDRUCK 33 bar Ol SE55 GO N O oor M Fig 4 Type designation with refrigerant Machine number Year of construction Minimum speed Maximum speed Theoretical volume flow rate low pressure stage at 1450 rpm Theoretical volume flow rate high pressure stage at 1450 rom Max permissible operating overpressures HP pressure side LP suction side Grade of oil filled in the factory ae a ae a o 9 The stated pressure and suction overpressures are not maximum values referred to the refrigerant The corresponding limits of application stated on page 6 7 apply to the various refrigerants 6 Type key example FZX 16 2051 R404A Ester oil filling filled in the factory for R 404A and R410A Size Code Permissible refrigerant inlet valve version Operating instructions n two sta mpressor FZ 1 mee eter co
11. mpress S E 0 112 01 00 Art No 09998 Page 6 KALTEMASCHINEN 7 Limits of application 7 1 Absolute limits of application Discharge end temperature t max 140 C Max permissible operating overpressure Speeds nL 1400rpm Pressure side HP 25bar n 1800rpm Suction side LP 19bar 7 2 Limits of application FZ 16 2051 R 22 Coolant R 22 t min 60 C S max 60 C 7 3 Limits of application FZX 16 2051 R 404A Coolant R 404 A tmin 7 60 C te max 92 5 C 7 4 Limits of application FZ 16 2051 R410A Coolant R 410 A te min 65 C Lage 41 C Definitions evaporation temperature condensing temperature II Operating instructions st ompressor FZ 1 Open two stage compress 6 Eizo Art No 09998 Page 7 KALTEMASCHINEN Explanations for figs 5 to 7 Compressor FZ 16 2051 may only be operated within the range of the illustrated diagrams Correct allocation of the refrigerants must be observed FZ 16 2051 R22 may only be operated with R 22 FZX 16 2051 H 404 A may only be operated with R 404 A FZX 16 2051 R410A may only be operated with R 410 A The absolute limits of application stated in 7 1 must be observed As a general rule e The compressor is equipped with heat protection thermostats as a standard feature connection is recommended e Use only thermally highly stable oils see extract from the lubrica
12. nt table pate 17 table 2 Recommendation for R 22 Bock standard oil FUCHS DEA RENISO SP 46 for R 404 A and R 410A Bock standard oil FUCHS DEA RENISO TRITON SE 55 e Continuous operation at the limit is not recommended Note The expansion valve position 25 fig 1 of the intermediate cooler is rated for the corresponding refrigerant see nameplate and adjusted in the factory for the whole application range Re adjustment is not necessary 8 Description of functions FZ 16 2051 see fig 8 page 8 The refrigerant sucked out of the evaporator 21 is compressed by the 4 cylinders on the LP stage 2 to the intermediate pressure p The overheated refrigerant then flows through the intermediate pressure chamber 3 where it is cooled down by an intermediate cooling system to reduce the discharge end temperature The intermediate cooling system consists of the following components intermediate cooler 6 expansion valve 7 sight glass 1 8 and 2 9 of the liquid pipe solenoid valve 10 filter drier 11 The cooled refrigerant is then sucked in through the intermediate pressure pipe 4 by the two cylinders of the HP stage 5 compressed to end pressure and conveyed to the condenser 15 After the refrigerant receiver 16 the liquid pipe divides into two pipes Pipe 1 goes through the panel heat exchanger 6 and brings the sub cooled refrigerant to the evaporator 21 Pipe 2 refrigerant is injected into the panel
13. ocation and arrangement of the valves see page 4 Opening the shut off valve a Turn spindle 1 to the left anti clockwise as far as it will go shut off valve fully open service connection 2 closed position A fig 11 Position A 2 Fig 11 Compressor Opening the service connection 2 b Turn the spindle 1 1 turn to the right service connection 2 open shut off valve open position B fig 12 Service connection 3 cannot be shut off always open Position B Fig 12 Note Before opening or closing the shut off valve loosen the valve spindle seal by turning about turn Tighten again after activating the shut off valve fig 13 Fig 13 Operating instructions n two st ompressor FZ 1 Rag S E 0 112 01 00 Art No 09998 Page 11 KALTEMASCHINEN 10 Initial commissioning The compressor has undergone a trial run in the factory and all functions have been checked Special running in instructions do not need to be observed Caution The machine is under pressure inert gas The pressure must be relieved before connecting up to the refrigeration system or before any work on the machine Depending on the operating conditions surface temperatures of up to 100 C can be reached on the pressure side respectively below 0 C on the suction side 10 1 Leak test evacuating e Proceed with a leak test for the refrigerating plant without including the compressor preferably N dr
14. s the lubricating ability of the oil When the compressor starts up again the reduction in pressure causes the refrigerant contained in the oil to evaporate out again This can result in oil foaming and oil migration causing oil shocks under certain circumstances In order to avoid damage to the compressor FZ 16 2051 compressors are equipped with oil sump heating as a standard feature The oil sump heating should always be connected up and kept running Operation notes The oil sump heating is in operation during standstill of the compressor When starting the compressor the oil sump heating switches off Note The oil sump heating must be connected up to a separate current circuit via an auxiliary contact or parallel wired auxiliary contactor of the compressor contactor It may not be connected up to the current circuit of the safety control chain Electrical data 230 V 140 W 10 7 Heat protection thermostat The FZ 16 2051 compressor is equipped with a bi metal heat protection thermostat The thermo contact switch protects the compressor from intolerably high compressed gas temperatures The heat protection thermostat is mounted on the hot vapour side of the compressors to the HP cylinder head Technical data for the heat protection thermostat Switching voltage max 250 V Switching current max 1 6 A at 250 V Switching off temperature 145 C 5K Switching on temperature approx 115 C The thermostat is to be wired
15. the compressor is short circuited internally and has no output e f an HP valve plate is mounted to one of the two LP cylinder heads this can cause an intolerably high increase in pressure in the cylinder head risk of bursting The HP valve plate is therefore marked with FZ16 1 HP stage and has a locking pin dia 5 mm The locking pin may not be removed and must engage in the hole of the HP cylinder head when mounting the valve plate LP valve plate HP valve plate Operating instructions Open two stage compressor FZ 16 E 0 112 01 00 Art No 09998 Page 17 KALTEMASCHINEN e Installation position valve plates suction gas hole LP valve plate intermediate pressure hole safety valve locking pin marking FZ16 1 HD stage HP valve plate 12 5 Excerpt from the lubricant table For FZ 16 2051 R 22 Bock standard oil grade Recommended alternatives FUCHS DEA Reniso SP 32 CHEVRON Zerol 150 FUCHS DEA Reniso SP46 MOBIL SHC 425 SUNOIL Suniso 3 GS TEXACO Capella WF 32 For FZX 16 2051 R 404 A and FZX 16 2051 R 410 A Bock standard oil grade Recommended alternatives FUCHS DEA Reniso Triton SEZ 32 FUCHS DEA Reniso Triton SE55 ICI Emkarate RL 32 H S MOBIL Arctic EAL 32 Other suitable oil types on request Table 2 E 0 112 01 00 Art No 09998 Page 18 KALTEMASCHINEN Operating instructions Open two stage compressor FZ 16 13 Technical dat
16. uctions st ompressor FZ 1 Open two stage compres 6 eaten Art No 09998 Page 15 KALTEMASCHINEN 11 Operation 11 1 Start unloader The FZ 16 compressor cannot be equipped with the normal start unloader integrated in the cylinder cover The division into LP and HP stage means that the normal start unloader available as accessory would only provide partial unloading in the LP stage External start unloading is therefore to be provided by pipes pipe diameter 22 mm with solenoid valve The solenoid valve must be suitably fastened to avoid vibration fractures in the pipeline Caution The solenoid valve of the intermediate cooling system page 8 fig 8 position 10 must be closed when operating with start unloader 11 2 Defrosting To guarantee troublefree operation of the refrigerating plant we recommend defrosting the evaporator by means of an electrical defroster device rather than using hot gas 12 Maintenance 12 1 Safety instructions Caution AN Before any work is carried out on the compressor e Switch the machine off and secure it to prevent it being switched on again e Relieve the system pressure in the machine After maintenance work has been completed e Connect up the safety switch and check functions e Evacuate the compressor e Remove the switching on safeguard 12 2 Service intervals In order to guarantee optimum operating safety and service life of the compressor we recommend carrying out the following s
17. up in sequence with the control line Operating instructions n two sta mpressor FZ 16 Ope Stage comp E 0 112 01 00 Art No 09998 Page 14 KALTEMASCHINEN 10 8 Shaft seal The compressor shaft is sealed to the outside by means of a shaft seal page 4 fig 2 position 8 The sealing element turns with the shaft The following is particularly important for troublefree operation e The entire refrigerant circuit must be properly designed and completely clean on the inside e Extreme jolts and vibrations on the wave are to be avoided together with continuous intermittent operation e The sealing surfaces can stick together when the machine is at a standstill for longer periods of time The machine should be started up briefly every 4 weeks Caution Failure to conform with this recommendation can cause a loss of refrigerant and damage to the shaft seal Note e The shaft seal seals off and lubricates with oil A certain oil leak few oil drops is therefore normal this applies in particular to the running in phase 200 300 hours e The shaft seal cover is equipped with an oil drain hose for controlled removal of the leaking oil A suitable receptacle is to be provided by the customer fig 15 shaft seal cover oil drain hose receptacle to be provided by the customer Fig 15 e Replacement of a shaft seal is described in the corresponding spare parts kit Operating instr
18. w pressure stage to high pressure stage 2 1 Intermediate cooling with panel heat exchanger for effective reduction of the discharge end temperature on the high pressure side The panel heat exchanger and all components required for intermediate cooling are completely mounted on the compressor with all pipes connected e There are 3 compressor versions depending on the refrigerant being used with differences in the injection valves for R 22 FZ 16 2051 R22 Art No 11730 forR 404A FZX 16 2051 R404A Art No 11728 forR 410A FZX 16 2051 R410A Art No 11729 The injection valve version is indicated by the refrigerant type in the compressor type designation e g FZ 16 2051 R22 Operating instructions Open two stage compressor FZ 16 4 Main and function parts 22 24 21 1 2 3 12 10 11 1516 13 14 Fig 3 Po M M M M M M M AH mi HSH mi mi aes NOAKGONASOBNATDROYA5 O et i cake E E 0 112 01 00 Art No 09998 Page 4 KALTEMASCHINEN Compressor housing Cylinder cover low pressure side LP Valve plate low pressure side LP Cylinder cover high pressure side HP Valve plate high pressure side HP Middle pressure chamber Base plate Shaft seal Compressor belt pulley Oil drain valve Oil pressure safety switch Oil intake plug Oil pump Oil sight glass Oil filter Oil sump heating Heat protection thermometer Suction shut off valve SV Pressure shut off valve DV Intermediate cooler Sight g
19. y instructions e Only qualified staff are allowed to handle refrigerating compressors Local safety A regulations accident prevention regulations technical rules etc must be observed e Caution The compressor is under pressure inert gas Relieve the pressure before connecting up to the refrigerating system or before starting any work on this machine e Note the max permissible operating pressure see nameplate e These instructions describe the FZ 16 compressor in the standard version e lf you have any queries please contact our technical service department phone 07022 9454 0 or speak to our representative 2 Open two stage compressor FZ 16 The FZ 16 compressor by BOCK is a two stage open reciprocating compressor with intermediate cooling for economic use in the extended deep cooling range Depending on the refrigerant used evaporation temperatures of down to t 65 C are possible The advantages compared to single stage compression include among others Low discharge end temperatures Favourable pressure conditions and thus low load on the power plant and valve system Low specific power requirements and other low operating costs 3 Brief description Open two stage six cylinder reciprocating compressor Cylinders arranged in W shape Operates with the counterflow principle Automatic lamella inlet and outlet valves in the cylinder heads Valve plate specially tuned on the high pressure side Displacement ratio lo

Operating instructions Open two-stage compressor FZ 16

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